Surgical gown having an adhesive tab and methods of use

ABSTRACT

A disposable surgical gown includes a front portion, a pair of sleeves, and first and second back portions. The first back portion includes an adhesive tab which extends from the first back portion to overlap at least a portion of the second back portion when the surgical gown is donned by a wearer. The adhesive tab is configured to overlap to adhere to the gown in a worn position. The adhesive tab includes a pull tab at a free end thereof to permit a wearer to grasp the pull tab to easily set and release the adhesive tab to and from the surgical gown.

BACKGROUND

This invention relates to protective attire commonly used in medical or industrial environments, and so forth. More particularly, this invention relates to surgical gowns having an adhesive tab which permits closure of the gown.

As is generally known, sterile surgical gowns are designed to greatly reduce, if not prevent, the transmission through the gown of liquids and biological contaminates which may become entrained therein. In surgical procedure environments, such liquid sources include the gown wearer's perspiration, patient liquids such as blood, salvia, perspiration, life support liquids such as plasma and saline, and so forth.

Many surgical gowns were originally made of cotton or linen and were sterilized prior to their use in the operating room. These gowns, however, permitted transmission or “strikethrough” of many of the liquids encountered in surgical procedures. These gowns were undesirable, if not unsatisfactory, because such “strikethrough” established a direct path for transmission of bacteria and other contaminates which wick to and from the wearer of the gown. Furthermore, the gowns were costly, and, of course, laundering and sterilization procedures were required before reuse.

One use, non-reusable, disposable surgical gowns have largely replaced linen and/or cotton surgical gowns. Because many surgical procedures require generally a degree of liquid repellency of at least a significant portion of the gown to prevent strikethrough, disposable gowns for use under these conditions are, for the most part, made from liquid repellent fabrics, or fabrics having a barrier material in at least one layer or ply of a multilayer or multiply fabric which is liquid repellant.

Such gowns, however, like their linen counterparts, when worn over other surgical clothing, can be hot and cause discomfort to the wearer. In addition, many gowns are complicated to don or put on, especially in a sterile environment, when surgical gowns must be changed periodically as they become contaminated by liquids, particulate matter, and so forth.

Therefore, there is a need for surgical gowns which have reasonable barrier properties, and some degree of light weight. In addition, there is a need for surgical gowns which are easy to put on, and which are readily adjustable about the girth of a wearer.

Such surgical gowns desirably include lighter weight material which may be positioned in non-essential areas which are less likely to be contaminated by liquids, particulate matter, and so forth, such as, by way of non-limiting example, the upper sleeves, the back portion, and the lower front portion of the surgical gown.

Such surgical gowns would desirably be easy for a wearer to put on and take off before, during and/or after surgical procedures. Accordingly, an adhesive tab including a pull tab is desirably provided on the gown. Such an adhesive tab and pull tab would desirably provide easy of connection and release to the gown, and adjustability of the gown to the individual wearer.

SUMMARY OF THE INVENTION

In response to the difficulties and problems discussed above, a non-reusable, disposable surgical gown, is provided, which includes a front portion, a pair of sleeves, and first and second back portions. The first back portion includes an adhesive tab which extends from the first back portion to overlap at least a portion of the second back portion when the surgical gown is donned by a wearer. The adhesive tab is configured to overlap to adhere to the gown when the gown is positioned on a wearer in a worn position. The adhesive tab includes a pull tab at a free end thereof to permit a wearer to grasp the pull tab to easily set and release the adhesive tab to and from the surgical gown.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of a front side of the present invention, showing the adhesive tab folded back into an unworn position before the surgical gown is donned;

FIG. 2 is a schematic plan view of a back side of the surgical gown of FIG. 1, showing the first back panel overlapped on itself and a release strip positioned over an adhesive strip;

FIG. 3 is a schematic plan view of the back side of the surgical gown similar to FIG. 2, but showing the release strip partially removed from the adhesive strip;

FIG. 4 is schematic plan view of the back side of the surgical gown similar to FIG. 3, but showing the first back panel overlapping the second back panel;

FIG. 5 is schematic plan view of the surgical gown of FIGS. 1-4 in a worn position on a wearer, with the adhesive tab positioned laterally and just above the hip of the wearer;

FIG. 6 is a sectional view of the adhesive tab of FIG. 5 taken at lines 6-6;

FIG. 7 is schematic plan view of another embodiment of the present invention, showing a front side of a surgical gown.

FIG. 8 is schematic plan view of the surgical gown of FIG. 7, showing a back side of the surgical gown and an adhesive tab thereon in an unbonded position;

FIG. 9 is a schematic plan view of the surgical gown if FIG. 8, but showing the back side of the surgical gown and the adhesive tab in a bonded position, holding the gown in a worn position;

FIG. 10 is a sectional view of the adhesive tab of FIG. 8 taken along lines 10-10; and

FIG. 11 is a sectional view of the adhesive tab of FIG. 9 taken along lines 11-11.

DEFINITIONS

As used herein the following terms have the specified meanings, unless the context demands a different meaning, or a different meaning is expressed; also, the singular generally includes the plural, and the plural generally includes the singular unless otherwise indicated.

As used herein, the terms “comprises”, “comprising” and other derivatives from the root term “comprise” are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, but do not preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

As used herein, the terms “fabric” or “material” refers to all woven, knitted and nonwoven fibrous webs, unless one type is specified. The terms “fabric” or “material” is used broadly herein to mean any planer textile structure produced by interlacing yarns, fibers or filaments. Thus, the fabric can be a woven or nonwoven web, either of which is readily prepared by methods well-known to those having ordinary skill in the art. For example, nonwoven webs are prepared by such processes as meltblowing, coforming, spunbonding, carding, air laying, and wet laying. Moreover, the fabric can consist of a single layer or multiple layers. In addition, a multilayered fabric can include films, scrim, and other non-fibrous materials. Desirable materials or fabric(s) are disclosed, for example, in U.S. Pat. No. 6,037,281 issued to Mathis et al., and in U.S. Pat. No. 5,695,868, issued to McCormick, both of which are incorporated by reference herein in their entirety.

As used herein, the term “layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.

As used herein the term “meltblown fibers” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al. which is incorporated by reference herein in its entirety. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than 10 microns in average diameter, and are generally tacky when deposited onto a collecting surface.

As used herein “multi-layer laminate” means a laminate wherein some of the layers are spunbond and some meltblown such as a spunbond/meltblown/spunbond (SMS) laminate and others as disclosed in U.S. Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,169,706 to Collier, et al., U.S. Pat. No. 5,145,727 to Potts et al., U.S. Pat. No. 5,178,931 to Perkins et al. and U.S. Pat. No. 5,188,885 to Timmons et al. each of which are incorporated by reference herein in their entirety. Such a laminate may be made by sequentially depositing onto a moving forming belt first a spunbond fabric layer, then a meltblown fabric layer and last another spunbond layer and then bonding the laminate in a manner described below. Alternatively, the fabric layers may be made individually, collected in rolls, and combined in a separate bonding step. Such fabrics usually have a basis weight of from about 0.1 to 12 osy (6 to 400 gsm), or more particularly from about 0.75 to about 3 osy. Multi-layer laminates may also have various numbers of meltblown (M) layers or multiple spunbond (S) layers in many different configurations and may include other materials like films (F) or coform materials, e.g. SMMS, SM, SFS, SMS etc.

As used herein the terms “bonded” and “bonding” refer to the joining, adhering, connecting, attaching, or the like of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. Such bonding may occur for example, by adhesive, thermal or ultrasonic methods.

As used herein the term “thermal point bonding” or “thermal bonding” involves passing a fabric or web of fibers to be bonded between a heated calender roll and an anvil roll. When layers of fabric, or two or more fabrics, are thermally bonded, the fabric(s) is/are respectively, heated to a melting point, such that all pores, capillaries, and so forth, if any, in the material collapse and/or are sealed in the melting process. The integrity and continuity of the material is maintained (i.e., the material does not become too thin or perforated in the bonded areas).

The calender roll is usually, though not always, patterned in some way so that the entire fabric is not bonded across its entire surface (thermal point bonding), and the anvil roll is usually flat. As a result, various patterns for calender rolls have been developed for functional as well as aesthetic reasons. One example of a pattern has points and is the Hansen Pennings or “H&P” pattern with about a 30% bond area with about 200 bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen and Pennings, incorporated herein by reference in its entirety. The H&P pattern has square point or pin bonding areas wherein each pin has a side dimension of 0.038 inches (0.965 mm), a spacing of 0.070 inches (1.778 mm) between pins, and a depth of bonding of 0.023 inches (0.584 mm). The resulting pattern has a bonded area of about 29.5%. Another typical point bonding pattern is the expanded Hansen Pennings or “EHP” bond pattern which produces a 15% bond area with a square pin having a side dimension of 0.037 inches (0.94 mm), a pin spacing of 0.097 inches (2.464 mm) and a depth of 0.039 inches (0.991 mm). Another typical point bonding pattern designated “714” has square pin bonding areas wherein each pin has a side dimension of 0.023 inches, a spacing of 0.062 inches (1.575 mm) between pins, and a depth of bonding of 0.033 inches (0.838 mm). The resulting pattern has a bonded area of about 15%. Yet another common pattern is the C-Star pattern which has a bond area of about 16.9%. The C-Star pattern has a cross-directional bar or “corduroy” design interrupted by shooting stars. Other common patterns include a diamond pattern with repeating and slightly offset diamonds with about a 16% bond area and a wire weave pattern looking as the name suggests, e.g. like a window screen, with about a 19% bond area. Typically, the percent bonding area varies from around 10% to around 30% of the area of the fabric laminate web. As is well known in the art, the spot bonding holds the laminate layers together as well as imparts integrity to each individual layer by bonding filaments and/or fibers within each layer.

As used herein, the term “ultrasonic bonding” or “ultrasonic welding” means a process performed, for example, by passing a fabric, such as a nonwoven material, between a sonic horn and anvil roll as illustrated in U.S. Pat. No. 4,374,888 to Bornslaeger, incorporated by reference herein in its entirety. When layers of fabric, or two or more fabrics, are ultrasonically bonded, the fabric(s) is/are respectively, heated to a melting point, such that all pores, capillaries, and so forth, if any, in the material collapse and/or are sealed in the melting process. The integrity and continuity of the material is maintained (i.e., the material does not become too thin or perforated in the bonded areas).

As used herein, the terms “nonwoven” and “nonwoven fabric” mean either a nonwoven web, a film, a foam sheet material, or a combination thereof.

As used herein the terms “fibrous nonwoven” and “fibrous nonwoven fabric or web” mean a web having a structure of individual fibers, filaments or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Fibrous nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of fibrous nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).

As used herein, the terms “surgical gown” and “protective attire” shall encompass medical garments or medical workwear and other forms of protective attire used by various industries/professions to protect workers from contaminants or to prevent the contamination of others. Such protective attire includes but is not limited to hospital and surgical gowns, medical scrubs, medical drapes, coveralls, and garments used to protect either a portion of, or an entire body. For the purposes of this application, the terms “garment(s)” and “apparel” are used synonymously.

As used herein the term “spunbonded fibers” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al. each of which are incorporated by reference herein in their entirety. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and often have average diameters (from a sample of at least 10) larger than 7 microns, more particularly, between about 10 and 20 microns.

As used herein, the related term “hydrophobic” shall generally refer a nonwoven fabric that does not promote the spreading of water. The water instead, forms drops and a contact angle that can be measured from the plane of the fiber/material surface, tangent to the water surface at the three-phase boundary line (air-water-fiber). Typically the contact angle ranges from 40-110 degrees, and is often greater than 90 degrees. The fiber/material also demonstrates a surface tension or energy of less than about 50 dynes/cm, such as between about 10-50 dynes/cm. Further elaboration on hydrophobic materials may be found in Hydrophobic Surfaces, edited by F. M. Fowkes of the Academic Press, New York, 1969, page 1. Hydrophobic fabrics may be produced from materials that are inherently hydrophobic or from hydrophilic fibers/films that have been treated in some fashion to be hydrophobic. Such treatment may include chemical treatments.

Contact angles can be measured by standard measurement techniques such as those described in the Introduction to Colloid and Surface Chemistry by Duncan J. Shaw, Third Edition, Butterworths 1980, pages 131-135, incorporated herein by reference. Surface energy of materials can be measured using dyne pen sets, such as those available from UV Process Supply, Inc., of Chicago, Ill. However, additional methods of measuring surface energy include Torsion Balance apparatus and other devices, which utilize platinum rings, such as those available from Torsion Balance Supplies of the United Kingdom.

As used herein, the term “wick” or “wicking” shall mean to carry moisture/liquid away, typically by capillary action. Such term also encompasses the ability of a liquid to travel between sheet materials, such as between the surface of a fibrous nonwoven sheet material such as a surgical drape and a film sheet, such as a glove.

As used herein, the term “contaminant” shall mean a chemical agent or biological organism/pathogen that can potentially harm a human being or animal.

As used herein, the terms used to describe affixing the various layers or portions of the surgical gown together include “join”, “secure”, “attach” and derivatives and synonyms thereof. Such affixing may be accomplished by any of several conventional methods. By way of example and not limitation, these methods include stitching, gluing, heat sealing, zipping, snapping, ultrasonic or thermal bonding, using a hook and loop fastening system, and other mechanisms and methods familiar to those skilled in the art. Adhesives suitable for securing the various layers of the present invention together include construction adhesives and pressure sensitive hot-melt adhesives such as Findly H2096 or H2088. Findly adhesives are available from Findly Adhesive Inc. of Wauwatosa, Wis.

As used herein, the term “outer” or “outside” describes that surface of the garment or gown which faces away from the wearer when the garment is being worn.

As used herein, the term “inner” or “inside” refers to the surface of the garment or gown, or part thereof which faces either the clothes or body of the wearer.

As used herein, the term “particulate matter” refers to a substance formed of separate particles, i.e., one or more particles.

As used herein, the term “liquid” refers to any liquid, fluid, or mixture of gas and liquid; various types of aerosols and particulate matter may be entrained with such liquids.

These terms may be defined with additional language in the remaining portions of the specification.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to one or more embodiments of the invention, examples of which are illustrated in the drawings. Each example and embodiment is provided by way of explanation of the invention, and is not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the invention include these and other modifications and variations as coming within the scope and spirit of the invention.

Turning now to the drawings and with reference to FIGS. 1-6, protective attire or a surgical gown 10 is schematically illustrated. The surgical gown 10 is desirably formed from a single blank of fabric or material. The surgical gown 10 includes a front portion 12 configured to substantially cover the front torso and legs of a wearer. The surgical gown 10 includes a first back portion 14 and a second back portion 16 which cooperate in a worn position to cover the back torso and legs of a wearer. The first back portion 14 includes a tab 18 having an adhesive strip 20 (hereinafter “adhesive tab 18”) thereon. A pair of sleeves 22 are positioned on each lateral side of the surgical gown 10. Each sleeve 22 is generally tubular in configuration, and includes a free end 24. A cuff 26 is desirably secured or joined to each free end 24 of each sleeve 22, generally about a wrist opening. A seam 30 is positioned on each lateral side 32 of the surgical gown 10 joins the blank into the surgical gown 10. Each lateral side 32 is defined generally as the area on the surgical gown 10 itself, as opposed to the sleeves 22, which extends from a junction 34 of the sleeves 22 to the body 36 of the surgical gown 10 downward. A lower end 38 extends substantially about a wearer's legs when the surgical gown 10 is worn (FIGS. 1-5).

Alternatively, the blank may be formed about a figure, resulting in no seams (illustrated in FIGS. 7-9). In another alternative, the front portion 12, the first and second back portions 14, 16, and/or the sleeves 22 are provided as separate pieces which are joined together to form the surgical gown (not shown). Different surgical gowns and their method of manufacture are disclosed, for example, but not by way of limitation, in U.S. Pat. Nos. 3,803,640; 3,935,596; 3,988,781; 4,016,604; 4,214,320; 4,674,132; 4,982,448; 5,901,376; 6,115,839; 6,378,136, 6,564,386, and so forth.

The surgical gown 10 includes a neck opening 40 which is desirably rounded close to the front of the wearer's neck on the front portion 12 and “scooped” or lowered in back, when the first and second back portions 14, 16 are in a closed worn position. The back portions 14, 16 cooperate to provide a V-shape, a U-shape, or similar scooped, lowered closed configuration. Such a scooped, lowered configuration permits heat from a wearer's neck and upper back to escape, providing increased coolness and comfort to the wearer.

Referring now to FIGS. 2-4, the back of the surgical gown 10 is illustrated in an unworn position as is the front of the gown (FIG. 1). The adhesive tab 18 and a portion 42 of the first back portion 14 is folded back against itself, with the adhesive tab 18 loosely connected to the surgical gown 10 by an adhesive spot 44 (FIGS. 5 and 6) positioned on the outside of the adhesive tab 18. A portion of the adhesive strip 20 on the adhesive tab 18 is covered by a release strip 46.

The adhesive strip 20 and the adhesive spot 44 may be any configuration, shape, and/or combination of shapes, and so forth. The adhesive tab 18 may include a pull tab 48. The pull tab 48 is a non-adhesive area on a free end 50 of the adhesive tab 18 adjacent the adhesive strip 20, which permits a wearer to easily lift and grasp the non-adhesive portion (pull tab 48) of the adhesive tab 18 to release the adhesive tab 18 or to set the adhesive tab 18 in a position. In the present embodiment, the pull tab 48 includes an aperture 49 formed near the free end 50 of the adhesive tab 18, to permit a wearer to more easily grasp the pull tab 48. It will be understood that the aperture is a non-limiting feature, and is not required. An area on the pull tab 48 and/or the surgical gown 10 may include “pull indicia” thereon, such as, by way of non-limting example, the arrow shown on the pull tab 48 in FIGS. 4 and 5. The term “pull indicia” as used herein refers to and includes any word(s) (in any language) and/or any symbol(s) or pictoral representation, and any combination thereof, to indicate to a wearer the location and/or the purpose of the pull tab 48 and the adhesive tab 18. In this manner, the adhesive tab 18 is easily set on a certain position or location on the surgical gown 10. Similarly, the pull tab 48 permits the adhesive tab 18 to be easily released from its adhered position or location on the surgical gown 10.

The adhesive may be any adhesive which operates as shown and/or described herein. Desirably, the adhesive is a pressure sensitive adhesive, which are known in the art.

Referring now to FIGS. 3-5, to don or put on the surgical gown 10, a wearer removes the release strip 46 to expose additional adhesive strip 20 on the adhesive tab 18. The adhesive tab 18 is released from its overlapped position when the wearer grasps the pull tab 48 and lifts the adhesive tab 18 from its location on the surgical gown 10 by which it was adhered by the adhesive spot 44. The adhesive tab 18 desirably includes at least one adhesive spot 44 on the outside 51 and the adhesive strip 20 on the inside 52 of adhesive tab 18 (FIG. 6). Desirably, in the worn position, the adhesive tab 18 is secured to the surgical gown 10 by the adhesive spot 44. The adhesive tab 18 is released, and the first back portion 14 is then overlapped in a direction 53 over the second back portion 16. The adhesive tab 18 is desirably moved in a direction 54 and positioned on or near the adjacent lateral side 32 of the surgical gown 10, in a worn position. Such placement of the adhesive tab 18 may be on or near the seam 30 or more anterior, and onto the front portion 12 of the surgical gown 10, if the wearer has a relatively small girth. Alternatively, if the wearer has a relatively large girth, the placement may be more posterior, and on or near the seam 30 or on the second back panel 16 of the surgical gown 10.

It will be understood, in all embodiments shown and/or described herein, that no “landing area” is needed or desired on the surgical gown 10. As a result, the surgical gown 10 via the adhesive tab 18 and the pull tab 48 may be adjusted and re-adjusted as necessary about a wearer to promote increased comfort as well as easy removal, by the wearer lifting the pull tab 48 and releasing the adhesive tab 18 and re-setting the adhesive tab 18 in another position.

FIG. 6 illustrates the free end 50 of the adhesive tab 18 having the adhesive spot 44 on the outside 51 and the adhesive strip 20 on the inside 52 thereof. The pull tab 48 is positioned next to an edge 55 of the free end 50, so that a wearer may easily grasp the non-adhered pull tab 48 and/or extend a finger into the aperture 49 to lift the adhesive tab 18. Such a procedure is required to don the surgical gown 10, to adjust the surgical gown 10 about the wearer, and to release the adhesive tab 18, thereby permitting the wearer to remove the surgical gown 10.

The adhesive tab 18 shown in FIGS. 1-6 is shown as integrally formed with at least a portion of the surgical gown 10. It will be appreciated, however, that the adhesive tab 18 may be provided as a separate piece, and joined to the surgical gown 10 (FIGS. 8 and 9).

Turning back to FIGS. 1-6, the basis weight of the surgical gown is desirably between about 0.5 osy and about 3.0 osy. Certain areas of the surgical gown may include a fabric having a heavier basis weight. These areas of heavier basis weight are desirably in areas or zones 56 most likely to be contacted and contaminated by liquids, particulate matter, and the like, during surgery, medical procedures, and so forth. These high contamination zones 56 may include an upper section of the front portion 12 covering a wearer's upper torso, and, desirably, a lower sleeve portion as well. Desirably, the fabric in these areas has a basis weight of about 1.45 osy to about 3.0 osy. Even more desirably, the fabric in these areas has a basis weight of about 1.45 osy to about 2.0 osy.

Similarly, certain areas or zones 58 of the surgical gown 10 may include a fabric having a lighter basis weight. These zones 58 of lighter basis weight allow the surgical gown 10 to be cooler and more comfortable to a wearer. These zones are less likely to be contacted and contaminated by one or more liquids, particulate matter, and so forth during procedures, such as surgery. These low contamination zones 58 include the a lower section of the front portion 12, covering a wearer's lower torso and legs, desirably, an upper sleeve portion of the sleeves 22, and the first and second back portions 14, 16. Desirably, the fabric in these areas has a basis weight of about 0.5 osy to about 1.44 osy. Even more desirably, the fabric in these areas has a basis weight of about 0.5 osy to about 1.3 osy.

Alternatively, the surgical gown 10 may utilize the same basis weight throughout. In this instance, the basis weight desirably is between 0.5 osy and about 3.0 osy. Such a basis weight may be used in both high contamination zones and low contamination zones. When an area of the surgical gown is overlapped, it will be appreciated that the basis weight will double.

The present invention is desirably used, for example, but not by way of limitation, with an improved cloth-like, liquid-impervious, breathable barrier material, such as that disclosed in U.S. Pat. No. 6,037,281, which is incorporated in its entirety herein, and which is discussed below in detail herein. The breathable barrier material possesses a unique balance of performance characteristics and features making the material suitable for use in forming surgical articles, as well as other garment and over-garment applications, such as personal protective equipment applications. The barrier material is a laminate comprising three layers—a top nonwoven layer formed, for example, of spunbond filaments, a bottom nonwoven layer formed, for example, of spunbond filaments, and a middle breathable film layer formed, for example, of a microporous film. The individual layers of barrier material are laminated, bonded or attached together by known means, including thermal-mechanical bonding, ultrasonic bonding, adhesives, and the like. As used herein, the terms “layer” or “web” when used in the singular can have the dual meaning of a single element or a plurality of elements. In anther alternative, the material is a nonwoven material of any type known in the art having a film or polymer layer or coating. Such a film or polymer layer or coating is desirably provided in a range of about 0.5 mils to about 3.0 mils.

Commercially available thermoplastic polymeric materials can be advantageously employed in making the fibers or filaments from which the top and bottom layers are formed. As used herein, the term “polymer” shall include, but is not limited to, homopolymer, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Moreover, unless otherwise specifically limited, the term “polymer” shall include all possible geometric configurations of the material, including, without limitation, isotactic, syndiotactic, random and atactic symmetries. As used herein, the terms “thermoplastic polymer” or “thermoplastic polymeric material” refer to a long-chain polymer that softens when exposed to heat and returns to the solid state when cooled to ambient temperature. Exemplary thermoplastic materials include, without limitation, polyvinyl chlorides, polyesters, polyamides, polyfluorocarbons, poly-olefins, polyurethanes, polystyrenes, polyvinyl alcohols, caprolactams, and copolymers of the foregoing.

Nonwoven webs that can be employed as the nonwoven top and bottom layers can be formed by a variety of known forming processes, including spunbonding, airlaying, meltblowing, or bonded carded web formation processes. For example, the top layer and bottom layer are both spunbond nonwoven webs, which have been found advantageous in forming barrier material. Spunbond nonwoven webs are made from melt-spun filaments. The melt-spun filaments are deposited in a substantially random manner onto a moving carrier belt or the like to form a web of substantially continuous and randomly arranged, melt-spun filaments. Spunbond filaments generally are not tacky when they are deposited onto the collecting surface. The melt-spun filaments formed by the spunbond process are generally continuous and have average diameters larger than 7 microns based upon at least 5 measurements, and more particularly, between about 10 and 100 microns. Another frequently used expression of fiber or filament diameter is denier, which is defined as grams per 9000 meters of a fiber or filament.

Spunbond webs generally are stabilized or consolidated (pre-bonded) in some manner immediately as they are produced in order to give the web sufficient integrity and strength to withstand the rigors of further processing. This pre-bonding step may be accomplished through the use of an adhesive applied to the filaments as a liquid or powder which may be heat activated, or more commonly, by an air knife or compaction rolls. As used herein, the term “compaction rolls” means a set of rollers above and below the nonwoven web used to compact the web as a way of treating a just produced, melt-spun filament, particularly spunbond, web, in order to give the web sufficient integrity for further processing, but not the relatively strong bonding of later applied, secondary bonding processes, such as through-air bonding, thermal bonding, ultrasonic bonding and the like. Compaction rolls slightly squeeze the web in order to increase its self-adherence and thereby its integrity. An air knife, as its name implies, directs heated air through a slot or row of openings onto the web to compact and provide initial bonding.

An exemplary secondary bonding process utilizes a patterned roller arrangement for thermally bonding the spunbond web. The roller arrangement typically includes a patterned bonding roll and a smooth anvil roll which together define a thermal patterning bonding nip. Alternatively, the anvil roll may also bear a bonding pattern on its outer surface. The pattern roll is heated to a suitable bonding temperature by conventional heating means and is rotated by conventional drive means, so that when the spunbond web passes through the nip, a series of thermal pattern bonds is formed. Nip pressure within the nip should be sufficient to achieve the desired degree of bonding of the web, given the line speed, bonding temperature and materials forming the web. Percent bond areas within the range of from about 10 percent to about 20 percent are typical for such spunbond webs.

The middle breathable film layer can be formed of any microporous film that can be suitably bonded or attached to top and bottom layers to yield a barrier material having the unique combination of performance characteristics and features described herein. A suitable class of film materials includes at least two basic components: a thermoplastic elastomeric polyolefin polymer and a filler. These (and other) components can be mixed together, heated and then extruded into a mono-layer or multi-layer film using any one of a variety of film-producing processes known to those of ordinary skill in the film processing art. Such film-making processes include, for example, cast embossed, chill and flat cast, and blown film processes.

Generally, on a dry weight basis, based on the total weight of the film, the middle breathable film layer will include from about 30 to about 60 weight percent of the thermoplastic polyolefin polymer, or blend thereof, and from about 40 to about 70 percent filler. Other additives and ingredients may be added to the film layer 14 provided they do not significantly interfere with the ability of the film layer to function in accordance with the teachings of the present invention. Such additives and ingredients can include, for example, antioxidants, stabilizers, and pigments.

In addition to the polyolefin polymer, the middle breathable film layer also includes a filler. As used herein, a “filler” is meant to include particulates and other forms of materials which can be added to the film polymer extrusion blend and which will not chemically interfere with the extruded film but which are able to be uniformly dispersed throughout the film. Generally, the fillers will be in particulate form and may have a spherical or non-spherical shape with average particle sizes in the range of about 0.1 to about 7 microns. Both organic and inorganic fillers are contemplated to be within the scope of the present invention provided that they do not interfere with the film formation process, or the ability of the film layer to function in accordance with the teachings of the present invention. Examples of suitable fillers include calcium carbonate (CaCO3), various kinds of clay, silica (SiO2), alumina, barium carbonate, sodium carbonate, magnesium carbonate, talc, barium sulfate, magnesium sulfate, aluminum sulfate, titanium dioxide (TiO2), zeolites, cellulose-type powders, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivatives, chitin and chitin derivatives. A suitable coating, such as, for example, stearic acid, may also be applied to the filler particles.

As mentioned herein, the breathable film layer may be formed using any one of the conventional processes known to those familiar with film formation. The polyolefin polymer and filler are mixed in appropriate proportions given the ranges outlined herein and then heated and extruded into a film. In order to provide uniform breathability as reflected by the water vapor transmission rate of the film, the filler should be uniformly dispersed through-out the polymer blend and, consequently, throughout the film layer itself so that upon stretching pores are created to provide breathability. For purposes of the present invention, a film is considered “breathable” if it has a water vapor transmission rate of at least 300 grams per square meter per 24 hours (g/m2/24 hours), as calculated using the test method described herein. Generally, once the film is formed, it will have a weight per unit area of less than about 80 grams per square meter (gsm) and after stretching and thinning, its weight per unit area will be from about 10 gsm to about 25 gsm.

The breathable film layer used in the example of the present invention described below is a mono-layer film, however, other types, such as multi-layer films, are also considered to be within the scope of the present invention provided the forming technique is compatible with filled films. The film as initially formed generally is thicker and noisier than desired, as it tends to make a “rattling” sound when shaken. Moreover, the film does not have a sufficient degree of breathability as measured by its water vapor transmission rate. Consequently, the film is heated to a temperature equal to or less than about 5 degrees C. below the melting point of the polyolefin polymer and then stretched using an in-line machine direction orientation (MDO) unit to at least about two times (2×) its original length to thin the film and render it porous. Further stretching of the middle breathable film layer, to about three times (3×), four times (4×), or more, its original length is expressly contemplated in connection with forming middle breathable film layer. After being stretch-thinned, the middle breathable film layer should have an “effective” film gauge or thickness of from about 0.2 mil to about 0.6 mil. The effective gauge is used to take into consideration the voids or air spaces in breathable film layers.

Cuffs 26, as illustrated in FIGS. 1-5 and 7-9, are desirably attached to the sleeves 22 of the surgical gown 10, and may also be attached at the neck of each garment, and so forth (not shown). Such cuffs 26 are desirably made from elastic yarns formed from synthetic or natural materials. An example of a synthetic material for forming the elastic yarns is polyurethane. Spandex is an example of polyurethane-based elastomer. More particularly, spandex is a polyurethane in fiber form containing a thermoplastic polyurethane elastomer with at least 85% polyurethane content. Commercial examples of spandex include LYCRA, VYRENE, DORLASTAN, SPANZELLE and GLOSPAN. An example of a natural material for forming elastic yarns is natural rubber. Polyester, nylon, and combinations of any of the foregoing synthetic and/or natural elastic yarns may also be used. The use of these, and other materials to construct sleeves and/or cuffs is disclosed in U.S. Pat. No. 5,594,955, which is incorporated by reference in its entirety herein. In the present embodiment, the cuffs 26 are desirably sewn, thermally bonded, ultrasonically bonded, adhesively attached, and so forth to the free end 24 of each sleeve 22.

In another embodiment of the present invention, illustrated by FIGS. 7-11, an alternative surgical gown 110 is schematically illustrated. The surgical gown 110 is similar to the surgical gown 10, except that it is formed from a blank of fabric or material about a form such that it does not include any seam. The surgical gown 110 includes a front portion 114 configured to substantially cover the front torso and legs of a wearer. The surgical gown 110 includes a first back portion 114 which overlaps a second back portion 116 which together cooperate in a worn position to cover the back torso and legs of a wearer. The first back portion 114 includes a separate tab 118 having an adhesive 20 (“adhesive tab 118”) thereon. A pair of sleeves 122 are positioned on each lateral side of the surgical gown 10. Each sleeve 122 is generally tubular in configuration, and includes a free end 124. A cuff 26 is desirably secured or joined to each to each free end 124 of each sleeve 122, generally about a wrist opening 126. A lower end 138 desirably extends substantially about a wearer's legs when the surgical gown 110 is worn (FIGS. 7-9).

The surgical gown 110 includes a neck opening 140 which is desirably “scooped” or lowered in back; when the first and second back portions 114, 116 are in a closed worn position. The back portions 114, 116 cooperate to provide a V-shape as illustrated, a U-shape, or similar scooped, lowered closed configuration.

Referring now to FIGS. 8 and 9, the back of the surgical gown 110 is illustrated in an unworn position as is the front of the gown (FIG. 7). The adhesive tab 118 is connected to portion of the first back portion 114. The adhesive tab 118 may include a separate release strip (not shown) which is removed from the adhesive strip 20, similar to release strip 46 shown and described herein. Alternatively, the adhesive tab 118 may provide a portion of a release strip 146 on the adhesive tab 118 (FIGS. 10 and 11). In this alternative, the adhesive tab 118 is folded back onto itself until the surgical gown 110 is donned. At that time, the adhesive strip 120 is released from its own release strip 146 on the adhesive tab 118 so that it may connect to the surgical gown 110 to hold it in the desired worn position or configuration.

The adhesive may be any configuration, shape, and/or combination of shapes. The adhesive tab 118 desirably includes a pull tab 148; the pull tab 148 and/or the surgical gown 110 may include “pull indicia” as well.

The adhesive may be any adhesive which operates as shown and/or described herein. For all embodiments shown and/or described herein, desirably, the adhesive on a portion of the adhesive tab 18, 118 has strong shear and friction properties in an area 170. Desirably, the peels strength in the area 170 is sufficiently strong or adhesive so that the adhesive tab 18, 118 holds the surgical gown 10, 110 securely in the worn position. If the adhesive tab 18, 118 is removed after its initial application, it will be understood that this removal results in deformation of the fabric or material of the surgical gown 10, 110. In addition, the for all embodiments shown and/or described herein, desirably the adhesive on a portion of the adhesive tab 18, 118 near the pull tab 48, 148 has a week peal strength in an area 172. Desirably, the peel strength in the area 172 is less strong than that in area 170, so that at least a portion of the adhesive tab 18, 118 can be easily lifted, to facilitate adjustment of the fit of the surgical gown 10, 110 to a user, or to permit removal of the surgical gown 10, 110.

To don or put on the surgical gown 110, a wearer releases the adhesive strip 120 on the adhesive tab 118 from its own release strip 146. Desirably, the first back portion 114 is then overlapped over the second back portion 116. Thereafter, the adhesive tab 118 is overlapped near the outside of a lateral side 130 of the surgical gown 110, and secured near or at the lateral side 130, as described previously herein, to secure the surgical gown 110 in the worn position.

The surgical gown 110 may have high contamination zones and low contamination zones, as previously shown and described in detail herein. In addition, the surgical gowns 10 and 110 may include any feature or characteristic shown and/or described herein.

While the present invention has been described in connection with certain preferred embodiments it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims. 

1. A disposable surgical gown, comprising: a front portion, a pair of sleeves, and first and second back portions, the first back portion having an adhesive tab which extends from the first back portion to overlap at least a portion of the second back portion in a worn position when the surgical gown is donned by a wearer, the adhesive tab configured to overlap to adhere to the gown in the worn position, the adhesive tab having a pull tab at a free end thereof to permit a wearer to grasp the pull tab to easily set and release the adhesive tab to and from the surgical gown.
 2. The disposable surgical gown of claim 1, wherein seams connect the front portion to the first and second back portions.
 3. The disposable surgical gown of claim 1, wherein the gown is formed without seams.
 4. The disposable surgical gown of claim 1, wherein the adhesive includes a pressure sensitive adhesive.
 5. The disposable surgical gown of claim 1, wherein the adhesive tab requires no landing area for adhesion to and release from the surgical gown.
 6. The disposable surgical gown of claim 5, wherein the adhesive tab includes at least one adhesive spot on the inside and the outside of the adhesive tab.
 7. The disposable surgical gown of claim 1, wherein the pull tab is formed to include an aperture therein.
 8. The disposable surgical gown of claim 1, wherein the pull tab includes a non-adhesive area adjacent an adhesive which is configured to be easily grasped by a wearer.
 9. The disposable surgical gown of claim 8, wherein one of the gown and the pull tab includes pull indicia.
 10. The disposable surgical gown of claim 1, wherein at least a portion of the adhesive on the adhesive tab is protected prior to use by a release strip positioned over the adhesive.
 11. The disposable surgical gown of claim 1, wherein the basis weight for surgical gown is in a range of about 0.5 osy to about 3.0 osy.
 12. The disposable surgical gown of claim 11, wherein the basis weight for the surgical gown varies between high contamination zones and low contaminated zones.
 13. The disposable surgical gown of claim 12, wherein the upper front portion and a lower portion of the sleeves include high contamination zones.
 14. The disposable surgical gown of claim 13, wherein the basis weight of the fabric in the high contamination zones is in a range of about 1.45 osy to about 3.0 osy.
 15. The disposable surgical gown of claim 12, wherein the lower front portion, the upper portion of the sleeves, and the first and second back portions are included in low contamination zones.
 16. The disposable surgical gown of claim 15, wherein the basis weight of the fabric in the low contamination zones is about 0.5 osy to about 1.44 osy.
 17. The disposable surgical gown of claim 1, wherein the adhesive tab is positioned near the lateral side.
 18. The disposable surgical gown of claim 1, wherein the first and second back portions are configured to overlap to provide a scooped opening near a wearer's neck and upper back.
 19. The disposable surgical gown of claim 18, wherein the scooped opening is one of V-shaped and U shaped.
 20. The disposable surgical gown of claim 1, where the adhesive tab is integrally formed with the first back portion.
 21. The disposable surgical gown of claim 1, wherein the adhesive tab is formed separately and attached to the first back portion.
 22. A disposable surgical gown, comprising: a front portion, a pair of sleeves, and first and second back portions, at least a lower portion of the front portion and the first and second back portions formed from a material having a lower basis weight relative to a basis weight of a material forming a lower portion of the pair of sleeves, the first back portion having an adhesive tab which overlaps itself in an unworn position but which extends from the first back portion to overlap at least a portion of the second back portion when the surgical gown is donned by a wearer and the gown is disposed in a worn position, the adhesive tab configured to overlap to adhere to the gown in the worn position, the adhesive tab having a pull tab at a free end thereof to permit a wearer to grasp the pull tab to easily set and release the adhesive tab to and from the surgical gown.
 23. The disposable surgical gown of claim 22, wherein seams connect the front portion to the first and second back portions.
 24. The disposable surgical gown of claim 22, wherein the gown is formed without seams.
 25. The disposable surgical gown of claim 22, wherein the adhesive includes a pressure sensitive adhesive.
 26. The disposable surgical gown of claim 22, wherein the adhesive tab requires no landing area for adhesion to and release from the surgical gown.
 27. The disposable surgical gown of claim 26, wherein the adhesive tab includes at least one adhesive spot on the inside and the outside of the adhesive tab.
 28. The disposable surgical gown of claim 22, wherein the pull tab is formed to include an aperture.
 29. The disposable surgical gown of claim 22, wherein the pull tab includes a non-adhesive area adjacent an adhesive which is configured to be easily grasped by a wearer.
 30. The disposable surgical gown of claim 29, wherein one of the gown and the pull tab includes pull indicia.
 31. The disposable surgical gown of claim 22, wherein at least a portion of the adhesive on the adhesive tab is protected prior to use by a release strip positioned over the adhesive.
 32. The disposable surgical gown of claim 22, wherein the basis weight for surgical gown is in a range of about 0.5 osy to about 3.0 osy.
 33. The disposable surgical gown of claim 22, wherein the basis weight for the surgical gown varies between high contamination zones and low contaminated zones.
 34. The disposable surgical gown of claim 33, wherein the upper front portion and a lower portion of the sleeves include high contamination zones.
 35. The disposable surgical gown of claim 34, wherein the basis weight of the fabric in the high contamination zones is in a range of about 1.45 osy to about 3.0 osy.
 36. The disposable surgical gown of claim 33, wherein the lower front portion, the upper portion of the sleeves, and the first and second back portions are included in low contamination zones.
 37. The disposable surgical gown of claim 36, wherein the basis weight of the fabric in the low contamination zones is about 0.5 osy to about 1.44 osy.
 38. The disposable surgical gown of claim 22, wherein the adhesive tab is positioned near the lateral side.
 39. The disposable surgical gown of claim 22, wherein the first and second back portions are configured to overlap to provide a scooped opening near a wearer's neck and upper back.
 40. The disposable surgical gown of claim 39, wherein the scooped opening is one of V-shaped and U shaped.
 41. The disposable surgical gown of claim 22, where the adhesive tab is integrally formed with the first back portion.
 42. The disposable surgical gown of claim 22, wherein the adhesive tab is formed separately and attached to the first back portion.
 43. A disposable surgical gown, comprising: a front portion, a pair of sleeves, and first and second back portions, at least a lower portion of the front portion, a lower portion of the sleeves, and the first and second back portions configured to provide low contamination zones and formed from a material having a lower basis weight, the upper front portion and a lower portion of the sleeves configured to provide high contamination zones and formed from a material having a higher basis weight relative to the basis weight of the low contamination zones, the first back portion having an adhesive tab which overlaps itself in an unworn position but which extends from the first back portion to overlap at least a portion of the second back portion when the surgical gown is donned by a wearer and the gown is disposed in a worn position, the adhesive tab configured to overlap to adhere to the gown in the worn position, the adhesive tab having a pull tab at a free end thereof to permit a wearer to grasp the pull tab to easily set and release the adhesive tab to and from the surgical gown. 